Fastener system with stabilizer ribs

ABSTRACT

Fasteners, drivers, punches, fastener systems, and methods of making fasteners, drivers, punches, and fastener systems are disclosed herein. The fasteners, drivers, punches, and fastener systems include, in one example, stabilizing ribs and corresponding recesses.

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S.provisional patent application 62/360,741 filed on Jul. 11, 2016, whichis hereby incorporated by reference in its entirety herein.

BACKGROUND

Use of powered tools to drive threaded fasteners at high speed and hightorque loads results in high forces applied by the driver to thefastener. Although many threaded fastener drive systems, particularlythose with a driver-engageable recess in the fastener head, are designedto have surfaces that are engaged by corresponding surfaces on thedriver, such ideal surface-to-surface engagement, at best, is difficultto achieve in practice. Rather than surface-to-surface engagementbetween the driver and fastener, by which the driving load can bedistributed over a broad surface area, driver-recess engagement often isconcentrated in small areas or points. Further, this is exasperated whenthe driver-recess engagement is not in line.

This may result from a number of factors such as inconsistencies in themanufacture of the fastener or the driver, as well as difficultiesencountered in the field. Field-encountered difficulties may include,for example, misalignment of the driver and fastener or inability tofully seat the driver in the recess because of paint or other debristhat may have collected in the recess. Even slight misalignment betweenthe driver and the fastener, or a variation of the fastener or driverfrom design specifications, can result in substantial reduction in thearea of contact between the driver and fastener, in many cases resultingin near point-like contact of several portions of the driver andfastener. Application of high torque under such circumstancesnecessarily results in concentrated stresses in the materials of thedriver and the recess that, in turn, can lead to failure of thematerial, either by plastic deformation or fracture. Even slight plasticdeformation of the engagement surfaces of the recess and driver canadversely affect system performance. If the recess deforms to defineramp-like surfaces inclined from the vertical, the driver may “cam-out”of the recess under the influence of the applied load. Such cam-out isundesirable, not only because it results in premature or uncontrollabledisengagement of the driver and recess, but also because the suddenlydisengaged driver can slip onto and damage the work piece. Additionally,excessive stress in the driver blade while driving the fastener cancause the blade to deform in a manner that reduces the surface areacontact with the fastener and effectively shifts the region of contactradially inwardly, thereby reducing the effectiveness of driver-recessengagement and increasing the risk of failure.

It would be desirable to provide improvements in recessed head fastenersand drivers by which the foregoing and other difficulties are reduced oreliminated and stability is increased.

SUMMARY

Disclosed herein are various fasteners, fastener systems, drivers,punches, and methods of forming fasteners systems. Example fasteners mayinclude a driver-engageable recess formed at an end thereof, the recessincluding a central core having a bottom region and a plurality of wingsradiating outwardly from the central core, the wings each being definedby a pair of sidewalls and an outer transition surface adjoining thesidewalls, the outer transition surface extending from a top of therecess and connected to the bottom region and forming a bottom regiontransition edge at the intersection of the bottom region and the outertransition surface. In one example, a fastener may include an innertransition surface connecting a sidewall of a first wing to a sidewallof a second wing, the first and second wings being adjacent to eachother. In another example, the fastener may include a groove in an innertransition surface extending in a radially outward direction from theinner transition surface, the groove extending from a first distancefrom the bottom region transition edge to a second distance from thebottom region transition edge. In one particular example, the firstdistance is non zero. In one example, the groove extends to a top of therecess. And in yet another example the groove comprises a first andsecond groove walls, the first and second groove walls meeting at agroove apex, the groove apex being tapered radially inward toward alongitudinal axis of the fastener as the recess groove extends in adirection from the top of the recess toward the bottom region.

In one example, a groove apex is tapered at an angle of about 10.4degrees from the longitudinal axis of the fastener. In another example,there is an angle of about 50.4 degrees between a first and a secondgroove walls. In one example, a groove apex intersects the innertransition surface at the first distance from the bottom regiontransition edge. And in yet another example a bottom region has a bottomrecess tip that is a third distance from the bottom region transitionedge. An in one example the first distance is greater than about 0.04inches.

Disclosed herein are example fasteners, where, in one example a firstand second intersection lines, formed at the intersection of the firstand second groove walls with the transition surface, respectively, forman angle of between about 6.5-7.0 degrees between them. In anotherexample the inner transition surface is tapered at an angle of betweenabout 3.5 degrees and about 4.0 degrees from a longitudinal axis of thefastener. In one example at least one of the sidewalls further includesa relieved region defined radially inward of its associated outertransition surface to define a relatively raised torque pad between itsrespective outer transition surface and the relieved region, the torquepad being an elongate strip and extending longitudinally along a marginof the sidewall that adjoins the outer transition surface. And in yetanother example the recess comprises four wings and at least two of theinner transition surfaces have the recess groove. And in yet anotherexample at least one of the sidewalls is configured to define a segmentof a spiral. In one example, at least one of the inner transitionsurfaces includes an interference surface having a top and a distancefrom the top to the bottom region transition edge is less than the firstdistance.

Disclosed herein are fastener systems. In one example a fastenerincludes a central recess core having a bottom region. In one example afastener includes a plurality of wings radiating outwardly from thecentral recess core, the wings each being defined by a pair of recesssidewalls and a recess outer transition surface adjoining the recesssidewalls, the recess outer transition surface extending from a top ofthe recess and connected to the bottom region and forming a bottomregion transition edge at the intersection of the bottom region and theouter transition surface. And in another example, at least one recessinner transition surface connecting a recess sidewall of a first wing toa recess sidewall of a second wing, the first and second wings beingadjacent to each other. And in yet another example a recess includes agroove in the inner transition surface extending in a radially outwarddirection from the inner transition surface, the groove extending from afirst distance from the bottom region transition edge to a seconddistance from the bottom region transition edge. And in yet anotherexample, the first distance being non zero.

In one example a fastener system includes a driver for engaging therecess of a fastener, the driver including a shank portion and arecess-engaging portion formed at an end of the shank portion, therecess-engaging portion comprising a central driver core having an endregion and a plurality of lobes radiating outwardly from the drivercentral core, each lobe being defined by a pair of driver sidewalls anda driver outer transition surface adjoining the driver sidewalls, thedriver outer transition surface extending from the shank portion andconnected to the end region and forming an end region outer transitionedge at the intersection with the driver end region. And in yet anotherexample, at least one driver inner transition surface connecting adriver sidewall of a first lobe to a driver sidewall of a second lobe,the first and second lobes being adjacent to each other. In one example,a driver includes a stabilizing rib on the driver inner transitionsurface extending in a radially outward direction from the drivercentral core, the stabilizing rib extending from a first distance fromend region outer transition edge to a second distance from the endregion outer transition edge, the first distance being non-zero. And inyet another example the groove comprises a first and second groovewalls, the first and second groove walls meeting at a groove apex, thegroove apex being tapered radially inward as the recess groove extendsin a direction from the top of the recess toward the bottom region. Andin another example, a stabilizer rib comprises a first and second ribwalls, the first and second rib walls meeting at a rib apex, the ribapex being tapered radially inward as the stabilizer rib extends towardthe end region.

In one example, the groove apex is tapered at an angle with respect to alongitudinal axis of the fastener and the stabilizer apex is tapered atan angle with respect to a longitudinal axis of the driver, the grooveapex taper angle being larger than the stabilizer apex taper. And inanother example a groove apex is tapered at an angle of about 10.4degrees from the longitudinal axis of the fastener. And in anotherexample the stabilizer apex is tapered at an angle of about 7.5 and 8.5degrees from the longitudinal axis of the driver. And in yet anotherexample, there is an angle of about 50.4 degrees between the first andsecond groove walls. In one example wherein there is an angle of about70 degrees between the first and second stabilizer walls. In anotherexample, the groove apex intersects the inner transition surface at thefirst distance from the bottom region transition edge. And in yetanother example the stabilizer apex meets the inner transition surfaceat the first distance from the end region outer transition edge.

In one example of disclosed fastener systems, a first and secondintersection line, formed at the intersection of the first and secondgroove walls with the recess inner transition surface, respectively,form an angle of between about 6.5-7.0 degrees between the groove walls.In another example the driver inner transition surfaces are tapered atan angle with respect to the longitudinal axis of the driver and therecess inner transition surfaces are tapered at an angle with respect tothe longitudinal axis of the recess, the driver inner transition surfacetaper angle being less than the recess inner transition surface taperangle. And in yet another example the recess inner transition surface istapered at an angle of about 3.5-4.0 degrees, inclusive from alongitudinal axis of the fastener. And in another example the driverinner transition surface is tapered at an angle of about 2.25-2.75degrees, inclusive from a longitudinal axis of the fastener. And in yetanother example, at least one of the recess sidewalls further comprisesa relieved region defined radially inwardly of its associated recessouter transition surface to define a relatively raised torque padbetween the recess outer transition surface and the recess central core,the torque pad being an elongate strip and extending longitudinallyalong a margin of the sidewall that adjoins the outer transitionsurface.

In a further example, disclosed example faster systems include a recesshaving four wings and at least two of the inner transition surfaces havethe recess groove. In one example a driver includes at least one torquerib formed on at least one sidewall of at least one of the sidewalls ofthe lobes, the at least one torque rib being oriented to extendsubstantially perpendicular to the outer transition surface of the lobeand increasing in cross-sectional area in a radially outward direction.In another example, a radially outermost end of the at least one torquerib define the widest portion of the lobe. And in another example, atleast one torque rib is generally triangular in a transversecross-section. And in yet another example, at least one of the recessinner transition surfaces comprises an interference surface having a topdefined by a design recess interference region and a distance from thetop to the bottom region transition edge is less than the first distanceto the groove. In one disclosed fastener system, at least one of thedriver inner transition surfaces comprises an interference surfacehaving a top defined by a design driver interference region and adistance from the top to the end region outer transition edge is lessthan the first distance to the stabilizing rib. And in another examplefastener system, the fastener system includes a clearance distancebetween the top of the recess interference region and the groove. And inyet another example fastener system, the fastener system includes aclearance distance between the top of the driver interference region andthe rib.

Disclosed herein are methods of forming a threaded fastener. In oneexample method, the method includes forming a threaded fastener having adriver-engageable recess formed at an end thereof. In one example, themethod includes using a punch to form the recess, the punch including, acentral core having a bottom forming portion and a plurality of wingforming portions radiating outwardly from the central core, the wingforming portions each being defined by a pair of sidewall formingportions and an outer transition surface forming portion adjoining thesidewall forming portions, the outer transition surface forming portionconnected to the bottom region forming portion and forming a bottomregion transition edge forming portion at the intersection of the bottomregion forming portion and the outer transition surface forming portion.In another example method, the punch includes at least one innertransition surface forming portion connecting a sidewall forming portionof a first wing forming portion to a sidewall of a second wing formingportion, the first and second wing forming portions being adjacent toeach other. In yet another example method, the punch includes a grooveforming portion in the inner transition surface forming portionextending in a radially outward direction from the inner transitionsurface forming portion, the groove forming extending from a firstdistance from the bottom region transition edge forming portion to asecond distance from the bottom region transition edge forming portion,the first distance being non zero.

In one example method, the punch includes a groove forming portionhaving a first and second groove wall forming portions, the first andsecond groove wall forming portions meeting at a groove apex formingportion, the groove apex forming portion being tapered radially inwardtoward a longitudinal axis of the fastener as the recess groove formingportions extends in a direction from a body toward the bottom regionforming portion. In another example method, a punch includes a grooveapex forming portion is tapered at an angle of about 10.4 degrees fromthe longitudinal axis of the punch.

Additional details will be provided in the accompanying figures and thedetailed description below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial perspective view of an example fastener recess inaccordance with disclosed embodiments;

FIG. 2 is an end view of an example fastener recess in accordance withdisclosed embodiments;

FIG. 3 is a cross section view of the example fastener recess of FIG. 2in accordance with disclosed embodiments;

FIG. 4 is a perspective view of an example punch in accordance withdisclosed embodiments;

FIG. 5 is a perspective view of an example punch in accordance withdisclosed embodiments;

FIG. 6 is a side view of an example punch in accordance with disclosedembodiments;

FIG. 7 is a cross section of an example punch in accordance withdisclosed embodiments;

FIG. 8 is a cross section view of an example punch in accordance withdisclosed embodiments;

FIG. 9 is a perspective view of an example driver in accordance withdisclosed embodiments;

FIG. 10 is a side view of an example driver in accordance with disclosedembodiments;

FIG. 11 is an end view of an example driver in accordance with disclosedembodiments;

FIG. 12 is a cross section view of an example driver in accordance withdisclosed embodiments;

FIG. 13 is an end view of an example driver mated with an example recessin accordance with disclosed embodiments;

FIG. 14 is a cross section view of an example driver mated with anexample recess in accordance with disclosed embodiments;

FIG. 15 is a perspective view of an example driver being mated with anexample recess in accordance with disclosed embodiments;

FIG. 16 is a perspective view of an example driver mated with an examplerecess in accordance with disclosed embodiments;

FIG. 17 is a cross section view of an example driver mated with anexample recess in accordance with disclosed embodiments;

DETAILED DESCRIPTION

Like reference numerals throughout this specification refer to similarfeatures throughout the figures.

FIGS. 1-3 show various views of an example fastener recess. Fastener 100has a driver-engageable recess 102 formed in head 101. Thedriver-engageable recess is of polygonal form that may be defined asgenerally cruciform in plan. The recess includes a central core and aplurality of wings 103 that radiate outwardly from the central portion.The wings 103 are each defined by an installation sidewall 104, aremoval sidewall 106, which are separated from each other by an outertransition surface 108, which is shown as downwardly (away from the head101) and inwardly inclined. The sidewalls 104 and 106 are referred toherein as installation sidewalls 104 and removal sidewalls assuming aright handed fastener thread. An inner transition surface 110 extendsbetween the installation and removal surfaces of adjacent wings.

In one example, the wings 103 generally conform in dimension to that ofa standard cruciform shape, for example the dimensions described withrespect to various cruciform recesses within the Industrial FastenersInstitute's IFI Inch Fastener Standards Book, 9^(th) edition, 2014 (“theIFI standards”, see, for example, an excerpt of which is enclosed hereinas appendix A), which is herein incorporated by reference in itsentirety. For the remainder of this disclosure a reference to “standard”refers to those standards established by the IFI standards unlessotherwise specified. The inner transition surfaces 110, in one example,generally conform to the shape of a standard square recess, for examplethose square recesses described in the IFI standards. Modifications tothose standards will be apparent from the present disclosure. The recess102, having wings 103 and inner transition surfaces 110, along with acorresponding driver, may in one example generally conform to thevarious dimensions of a Phillips Square-Drive® (PSD) recess and driver,available as of this writing from Phillips Screw Company of Burlington,Mass., USA. However, features of the present disclosure may also beincorporated into non-driving surfaces of other fasteners and fastenersystems. For example, embodiments of the present disclosure can beincorporated into existing fastener designs, for example Phillips ScrewCompany's commercially available fasteners, for example, those availableunder the trade designations Pozidriv®, Torq-Set®, Tri-Wing®, PhillipsII®, Hexstix®, Torq-Set®, Mortorq®, Mortorq® Super, External Mortorq®Super, among other multi-winged fasteners having, for example, 2, 3, 4,5, 6, or more wings. In addition, those fasteners/drivers disclosed thatare, at least in part, defined by spiral segments, for example, thosedescribed in U.S. Pat. Nos. 5,957,645, 6,234,914, and 6,367,358 issuedto Stacy (the Stacy patents), U.S. Pat. Nos. 7,891,274, 8,171,826, and8,387,491 issued to Dilling (the Dilling patents), and U.S. provisionalpat. application No. 62/351,540 filed on Jun. 17, 2016 (the '540application), all of which are commonly owned with this application. Thedisclosures of these patents are incorporated herein by reference ineach of their entireties.

Continuing with the example embodiments of FIGS. 1-3, the outertransition surfaces 108 and the inner transition surfaces 110 merge intoa generally concave recess bottom region 120. The outer transitionsurfaces 108 meet the bottom region 120 at bottom region transition edge122. The inner transition surfaces 110 meet the bottom region 120 at theinner transition bottom edge 124. At least one inner transition surface110 includes a groove 112 within the inner transition surface 110. Thegroove 112 extends radially outward from the inner transition surface.Therefore, a driver conforming to the dimensions of the recess 102 willfit within the recess 102 whether or not the driver includes astabilizing rib (discussed in more detail below). The groove(s) 112interact with corresponding stabilizing rib(s) to stabilize the driverwithin the recess and to minimize rocking of the driver. This featurewill be discussed further below.

In one example, the recess 102 includes more than one inner transitionsurfaces 108 having a groove 112. For example, in one embodiment,diametrically opposed inner transition surfaces each have grooves 112.The recess 102 can include, for example, any number of pairs ofdiametrically opposed grooves 112. As shown in FIGS. 1-2, the recess 102includes two pairs of diametrically opposed grooves 112, or in thealternative one, three, four, or more pairs for recesses with differentconfigurations.

The groove 112, in one example, includes groove walls 114 connectedtogether at groove apex 115. The groove walls intersect the innertransition surfaces 110 at intersection lines 116. The angle between thegroove walls may be any angle configured to provide the desiredstability and also based on the size and configuration of the recess. Inone example, the angle between the groove walls 114 is between about 40degrees and about 60 degrees, or about 50.4 degrees for a PSD size 1-2recess. In one example, a PSD size nomenclature M-N refers to a PSDrecess/driver conforming to an “M” size square and a “N” sizePhillips/cruciform in accordance with sizes available from PhillipsScrew Company and as disclosed in the IFI standards.

The inner transition surfaces 110, in one example, are tapered inwardtoward the longitudinal axis of the fastener from the top of the recesstowards the bottom region 120. The taper of the inner transitionsurfaces 110 establishes interference surfaces 156 (indicated indiagonal markings) for providing an interference fit with cooperatingsurfaces of the corresponding driver.

One or both of the installation or removal sidewalls 104,106 may beprovided, in one example, with a relieved region 118 that extends fromthe upper edge of the corresponding sidewall 104,106 downwardly towardthe bottom of the sidewall. The relieved regions 118 are formed so thatthe unrelieved portion of their respective sidewall defines a torque pad119 in the form of a relatively raised strip that extends along theouter margin of its associated sidewall, that is, where the sidewallmeets with the outer transition surface 108 of the wing 103. The torquepad 119 is intended to be engaged by the most radially outward regionsof the lobes of the mating driver to assure that the driving torque willbe applied to the recess drive walls at the most radially outwardlocation of the recess drive walls. The relieved region 118 is designedand configured so that the driver blade, in one example, will not engagethose portions of the sidewalls 104, 106 defined by the relieved regions118. Additional information regarding example torque pads and relievedregions 118 may be found, for example in U.S. Pat. Nos. 6,223,634,6,601,482, and 6,786,827 to Hughes et al (“the '634 patents), which areherein incorporated by reference in their entirety. By maintainingengagement of the driver blades with the outermost regions of thesidewalls, the moment arm of the applied torque is maximized, therebyreducing the force necessary to develop the desired level of torque and,consequently reducing the risk of undesirable deformation of the recess.The top of the recess may also include head markings 140, which maycontact a top surface of the grooves 112 without detrimental impact tothe grooves 112.

With respect to FIG. 3, groove 112 begins a distance 152 from the bottomregion transition edge 122 and continues to the top of the recess 102,which is a distance 150 from the bottom region transition edge 122. Inone particular example, distance 152 is greater zero such that thegroove 112 does not extend to the bottom region 120 thus not interferingwith a stick fit feature. In one particular example, groove 112 has agroove clearance distance 154 greater than about zero from the top ofthe interference surface 156.

Disclosed example recesses may be formed by a heading punch adapted toform the head of the fastener with the disclosed corresponding recess.The recess can be formed in conventional heading techniques in, forexample, a two blow header. FIGS. 4-8 illustrate a punch 300 configuredto form an example disclosed recess. The punch is a positivecorresponding to the negative of the recess 102 embodiments describedwith respect to FIGS. 1-3. Thus, features and dimensions described withreference to disclosed punches 300 are also applicable to correspondingrecess 102 features and embodiments and vice versa.

The punch includes body portion 370 having a face 374 and an integralnib 376 that protrudes from the face 374. The nib 376 is the complementof the shape of the recess and the face of the punch is of complementaryshape to that of the intended screw head, shown here as a flathead. Withrespect to FIG. 5, the nib 376 includes a central core and a pluralityof wing forming portions 303 that extend generally radially andoutwardly from the core. Each wing forming portion 303, as shown,includes a relieved region forming portion 318 and a torque pad formingportion 319 forming the respective installation and removal sidewallforming portions 304, 306, and an outer transition surface formingportion 308. An inner transition surface forming portion 310 extendsbetween the installation and removal surface forming portions ofadjacent wings.

The outer transition surface forming portion 308 and the innertransition surface forming portions 310 merge into a bottom regionforming portion 320. The outer transition surface forming portions 308meet the bottom region forming portions 320 at bottom region transitionedge forming portion 322. The inner transition surface forming portions310 meet the bottom region forming portion 320 at the inner transitionbottom edge forming portion 324. At least one inner transition surfaceforming portions 310 includes a groove forming portion 312 in the innertransition surface forming portion 310. The groove forming portion 312extends radially outward from the inner transition surface formingportion 310.

The inner transition surface forming portions 310, in one example, aretapered inward toward the longitudinal axis of the punch 300 from thebody portion 370 towards the bottom region forming portion 320. Thetaper of the inner transition surface forming regions 310 establish (onthe corresponding formed recess) interference surfaces, which are shownon the punch as interference surface gauging area 356 (indicated indiagonal markings). The location of the resulting interference surfaceson the formed recess will depend on the size and configuration of therecess and the size and configuration of the driver used within therecess. For example, the resulting interference surface 156 (FIGS. 1 and3) are regions of the inner transition surface 110 in which thecorresponding driver is designed to make contact with the recess (beforeapplying installing or removing torque) and where an interference orstick-fit occurs between the recess and the driver. During manufactureand operation of the punch, the interference surface forming gaugingarea 356 can be checked (or gauged) to ensure interference surfacegauging area 356 fall within design tolerances. Provided the inferencesurface gauging area 356 is within tolerances, the interference fitbetween the recess and the driver should occur in the proper location,i.e. between the groove 112 and bottom region 120 of the recess andbetween the stabilizing rib 212 and the end region 220 of the driver,discussed below. This location of the interference surface/interferencesurface gauging area 356 can be altered, that is moved higher or lowerin the recess (and on the corresponding recess forming punch) dependingon the recess/driver design and at what recess depths an interferencefit is desired.

With reference to FIG. 6, the groove forming portion 312, in oneexample, includes groove wall forming portions 314 connected together atgroove apex forming portion 315. The groove wall forming portionsintersect the inner transition surface forming portions 310 atintersection lines 316. The angle between the groove wall formingportions may be any angle configured to provide the desired recessgroove. In one example, the angle δ (FIG. 8) between the groove wallforming portions 314 is between about 40 degrees and about 60 degrees,or about 50.4 degrees for a PSD size 1-2 recess. The angle α between theintersection lines 316, within the plane of the inner transition surfaceforming portion 310, is between about 6.5 and about 7.0 degrees,inclusive, for a punch design to form a recess for a PSD size 1-2recess.

The bottom region forming portion has a distance 350 between a tipforming portion 321 and the bottom region transition edge formingportion 322. The top 380 of the interference surface gauging area 356 isa distance 358 from the bottom region transition edge forming portion322 and has a distance 357 between the top 380 and bottom 382 of theinterference surface gauging area 356 defining, in one example, thelocation of acceptable design limits of the interference surface gaugingarea 356 for gauging. Distance 357, in one example may be between about0.001 inches and about 0.012 inches, inclusive. And in one example isabout 1 hundredth of an inch. Or, for example, about 0.012 inches. Andin another example, no more than 0.012 inches.

The top 380 of the interference surface gauging area 356 has a distance359 from a tip forming portion 321. Groove forming portion 312 maybegin, i.e., the point of intersection of intersecting lines 316 to eachother and the inner transition surface forming portion 310, at adistance 352 from the bottom region transition edge forming portion 322,resulting in a clearance distance 354 between the top 380 of theinterference surface gauging area 356 and the groove forming portion312.

The clearance distance 354 may be determined to provide clearance fromthe interference surface gauging area 356 such that the groove formingportion 312 will not interfere with gauging the interference surfacegauging area 356 of inner transition surfaces 310. Gauging is importantto ensure that formed fasteners are within tolerances. In one example,the clearance distance 354 may also depend on the desired amount ofengagement between the resulting groove and driver stabilizer rib,discussed in more detail below. In certain non-limiting examples, theclearance distance 354 may be between about 0.005 inches and about 0.011inches, inclusive, between about 0.005 and about 0.012 inches,inclusive, or about 0.011 inches.

Table 1 includes non-limiting examples of the dimension referencesdiscussed with reference to FIG. 6. The example dimensions are listedwith reference to corresponding PSD driver sizes. The drivers arecommercial available from Phillips Screw Company.

TABLE 1 (inches) DRIVE SIZE 359 354 357 350 352 358 PSD 0-1 .057 .005.012 .013 .049 .044 PSD 1-2 .052 .011 .012 .023 .040 .029 PSD 2-2 .074.011 .012 .023 .062 .051 PSD 3-3 .069 .011 .012 .039 .041 .030 DimensionFormulas: (359 + 354) − 350 = 352 359 − 350 = 358

With reference to FIG. 7, in one example, the distance 360 between theopposing inner transition surfaces 310 at the inner transition bottomedge forming portion 324 conforms to a standard square recess for therespective driver size. In one example, distance 360 is between about0.0852 inches and about 0.0842 inches, inclusive for a PSD 1-2 sizedriver. In one example, the inner transition surface forming portion(and resulting inner transition surfaces), are tapered inward toward thelongitudinal axis of the punch integral nib 376 toward the tip formingportion 321 at a taper angle β with respect to the longitudinal axis ofthe integral nib 376. In one example the taper angle β is between about3.5 degrees and about 4 degrees, inclusive. The taper angle taper angleβ will establish the interference fit with the driver as will bediscussed below. Therefore, other taper angles may also be appropriatein accordance with the design of the respective driver.

In one example, the groove apex forming portion 315 is tapered inwardtoward the longitudinal axis of the punch integral nib 376 toward thetip forming portion 321 at a groove apex taper angle γ with respect tothe longitudinal axis of the integral nib 376. In one example the grooveapex taper angle γ is between about 8 degrees and about 12 degrees,inclusive. In one example the groove apex taper angle γ is about 10.4degrees. The groove apex taper angle taper angle γ will establish thestabilizing effect with the driver as will be discussed below.Therefore, other taper angles may also be appropriate in accordance withthe design of the respective driver.

FIG. 8 shows a cross section of one example of a groove forming portion312. Groove forming portion 312 includes groove wall forming portions314 connected together at groove apex forming portion 315. The groovewall forming portions 314 intersect the inner transition surface formingportions 310 at intersection lines 316. The angle δ between the groovewall forming portions may be any angle configured to provide the desiredstability and based on the size and configuration of the recess. In oneexample, the angle δ is between about 40 degrees and about 60 degrees,or about 50.4 degrees for a PSD size 1-2 recess. However, other angleswill be apparent from the present disclosure.

FIGS. 9-13 show various views of an example driver 200. Driver 200 has arecess-engageable portion formed on a shank (not shown). The driver 200is of polygonal form that may be defined as generally cruciform in plan.The driver includes a central portion and a plurality of lobes 203 thatradiate outwardly from the central portion. The lobes 203 are eachdefined by an installation sidewall 204, a removal sidewall 206, whichare separated from each other by an outer transition surface 208, whichis shown as downwardly and inwardly inclined (assuming the driver tip221 is pointed down into a recess). The sidewalls 204 and 206 arereferred to herein as installation sidewalls 204 and removal sidewalls206 assuming the driver is installing or removing right handed fastenerthread. An inner transition surface 210 extends between the installationand removal surfaces 204, 206 of adjacent lobes 203.

In one example, the lobes 203 generally conform in dimension to that ofa standard cruciform shape or standard cruciform driver. The innertransition surfaces 110, in one example, generally conform to the shapeof a standard square driver, for example those square drivers describedin the IFI standard or otherwise dimensioned to engage with the standardrecesses described in the IFI standard. Modifications to those standardswill be apparent from the present disclosures. The recess engageableportion 202, in one example, has lobes 203 and inner transition surfaces210, that may, in one example, generally conform to the variousdimensions of a PSD driver, available as of this writing from PhillipsScrew Company. However, features of the present disclosure may also beincorporated into non-driving surfaces of other fasteners and fastenersystems. For example, embodiments of the present disclosure can beincorporated into existing driver designs, for example Phillips ScrewCompany's commercially available drivers, for example, those availableunder the trade designations Pozidriv®, Torq-Set®, Tri-Wing®, PhillipsII®, Hexstix®, Torq-Set®, Mortorq®, Mortorq® Super, External Mortorq®Super, among others multi-winged fasteners having, for example, 2, 3, 4,5, 6, or more wings. In addition, those fasteners/drivers disclosed thatare, at least in part, defined by spiral segments, for example, thosedescribed in the Stacy patents, the Dilling patents, and/or the '540application.

Continuing with the example embodiments of FIGS. 9-12, the outertransition surfaces 208 and the inner transition surfaces 210 merge intoa generally convex driver end region 220. The outer transition surfaces208 meet the end region 220 at end region outer transition edge 222. Theinner transition surfaces 210 meet the end region 220 at the end regioninner transition edge 224. At least one inner transition surface 210includes a stabilizing rib 212. The stabilizing rib 212 extends radiallyoutward from the inner transition surface 210. The stabilizing rib(s)212 interact with corresponding stabilizing groove(s) to stabilize thedriver within the recess and to minimize rocking of the driver.

In one example, the recess-engageable portion 202 includes more than oneinner transition surfaces 208 having a stabilizing rib 212. For example,in one embodiment, diametrically opposed inner transition surfaces 210each have stabilizing ribs 212. The recess-engageable portion 202 caninclude, for example, any number of pairs of diametrically opposedstabilizing ribs 212. As shown in FIGS. 9 and 11, the recess-engageableportion 202 includes two pairs of diametrically opposed stabilizing ribs212, or in the alternative one, three, four, or more pairs for driverswith different configurations.

The stabilizing ribs 212, in one example, includes rib walls 214connected together at rib apex 215 (FIG. 11). The rib walls 214intersect the inner transition surfaces 210 at intersection lines 216.The angle between the groove walls may be any angle configured toprovide the desired stability and also based on the size andconfiguration of the recess. In one example, the angle between the ribwalls 214 is between about 60 degrees and about 80 degrees, or about 70degrees for a PSD size 1-2 driver. In one example, the angle between therib walls 214 is greater than the angle δ between groove wall formingportions 314 (and the corresponding formed recess). In one examplehaving an angle between the rib walls 214 greater than the angle δbetween groove wall forming portions 314 (or groove walls 114) promotesstability and surface contact between the driver bit rib and the recessgroove when needed based on any imperfections of the primary squaresticking feature, for example at the inner transition surfaces. Further,it helps eliminate unwanted rock of the driver bit within the recessback and forth.

The inner transition surfaces 210, in one example, are tapered inwardtoward the longitudinal axis of the fastener from the shank of thedriver towards the end region 220/tip 221. The taper of the innertransition surfaces 210 establishes interference surfaces 256 (indicatedin diagonal markings) for providing an interference fit with cooperatingsurfaces of the corresponding recess.

One or both of the installation or removal sidewalls 204,206 may beprovided, in one example, with torque ribs 230. The torque ribs 230 canbe provided to reduce cam-out and other advantages disclosed within the'634 patents.

With respect to FIG. 10, stabilizing ribs 212 begin a distance 252 fromthe end region outer transition edge 222 and continues to a distance 250from the end region outer transition edge 222. In one example, thedistance 250 may end at the upper limit of lobes 203, or in anotherexample, continue past lobes 203. The edges of the inner transitionsurfaces 210, i.e., where the inner transition surfaces 210 meet thelobes 203 may form an angle ε, which may also conform to a correspondingrecess angle. In one example ε is about 1.5 degrees for PSD size 1-2driver. In one particular example, distance 252 is greater than zerosuch that the groove 112 does not extend to the bottom region 120. Inone particular example, stabilizing rib 212 has a rib clearance distance254 greater than about zero from the top of the interference surface256.

FIG. 11 shows an end view looking towards the tip 221 of driver 200having four lobes 203 and four stabilizing ribs 212. From this view itcan be seen that inner transition surfaces 210 are tapered inward towardthe tip 221.

FIG. 12 shows a cross section of FIG. 11. In one example, the distance260 between the opposing inner transition surfaces 210 at the end regioninner transition edge 224 conforms to a standard square driver size. Inone example, distance 260 is between about 0.0889 inches and about0.0879 inches, inclusive for a PSD 1-2 size driver. In one example, theinner transition surface, are tapered inward toward the longitudinalaxis of the driver at a taper angle ζ with respect to the longitudinalaxis of the driver 200. In one example the taper angle ζ is betweenabout 4.5 degrees and about 5.5 degrees, inclusive. In addition, thosefasteners/drivers disclosed that are, at least in part, defined byspiral segments, for example, the Stacy patents, the Dilling patents,and/or the '540 application. The disclosures of these patents areincorporated herein by reference in each of their entireties. In oneparticular example, the taper angle ζ is larger than taper angle β ofthe associated recess, thereby creating, in one example, an interferencefit in interference fit region 256. Other taper angles may also beappropriate in accordance with the design of the respective recess.

In one example, the stabilizing rib apex 315 is tapered inward towardthe longitudinal axis of the driver 200 toward the tip 221 at a grooveapex taper angle η with respect to the longitudinal axis of the integralnib driver 200. In one example, the groove apex taper angle η is betweenabout 6 degrees and about 10 degrees, or between about 7.5 degrees andabout 8.5 degrees, inclusive for a PSD 1-2 size driver. In one example,the groove apex taper angle taper angle η is less than the taper angle γof the corresponding recess groove 112 which can provide additionalclearance between the a stabilizing rib 212 and corresponding groove 112when mated. Other taper angles may also be appropriate in accordancewith the design of the respective recess.

FIG. 13 shows a top view of an example fastener 100 with driver 200inserted therein. The remaining portion of the driver including theshaft is not shown for clarity.

FIG. 14 shows a cross section view of FIG. 13 showing driver 200 engagedwithin recess 102. Dashed lines 264 has been added to indicate theprofile of the corresponding stabilizer ribs 212 outside of the dashedlines. The inner transition surfaces 110 and 210 in normal coaxialinsertion between the driver 200 and fastener 100 establish aninterference fit 456 preventing the driver tip 221 from bottoming out inthe recess. The amount and degree of stick fit can be manipulatedaccording to fastener and driver design requirements in accordance withthis specification. Further, in normal coaxial insertion between thedriver 200 and fastener 100, clearance 458 is present between thestabilizing rib 212 and groove 112. This clearance, in one example, mayalso be included in order to favor establishing a stick fit 456 over rib212 to groove 212 contact.

However, if the driver 200 were to be rocked within the recess 102, orinserted at an angle with respect to the longitudinal axis of the recess102, the stabilizing rib 212 would engage the corresponding groove 112to provide stability. Further, the stabilizing ribs 212 and grooves 112may also provide stability should the dimensions of the inner transitionsurfaces 210 or other driver dimensions be out of normal tolerances suchthat a desired stick fit 456 is not fully obtained.

With continuing reference to FIGS. 15 and 16, in one example, the driverlobe 203 and recess wings 103 may be configured such that a clearance458 (FIG. 16) is present between the outer transition surfaces 108, 208of the recess and drivers, respectively. This clearance 458 (FIG. 16)may be included to further ensure a stick fit 456 is established betweenrespective inner transition surfaces 110, 210 instead of bottoming thedriver outer transition surfaces 208 to the recess outer transitionsurfaces 108. In one non-limiting example, clearance 458 may be about0.0020 inches for a PSD 1-2 sized driver and corresponding recess. Inone non-limiting example, clearance 458 in between about 0.002 inchesand about 0.010 inches, inclusive for a PSD 0-1, 1-2, 2-2 and 3-3 sizeddrivers.

Increasing the stability of the driver, i.e., the driver axis is more inline with the recess axis, has a number of non-limiting advantages. Forexample, by maintaining stability of the driver within the recess, animproved stick fit 456 may occur which may increase the speed ofapplication fasteners to the work piece. Further the lobes 203 may haveimproved engagement with the wings 103 which will decrease cam-out anddrive/recess damage.

FIG. 17 shows and shows an example driver 200 engaged with examplefastener 100, as well as example, non-limiting dimensions inaccompanying table 2.

TABLE 2 (inches) DRIVE SIZE 550 552 554 556 PSD 0-1 .049 .033 .020 .036PSD 1-2 .040 .015 .035 .060 PSD 2-2 .062 .037 .035 .060 PSD 3-3 .041.020 .045 .066 Dimension Formulas: (554 + 550) − 552 = 556

In this manner a new and unique fasteners, drivers, punches, andfastener systems are presented that provides an improvement in stabilitycharacteristics with respect to the driver recess engagement and alsoimprove the overall performance of the fastener system.

It should be understood that the above description is only illustrativeof the invention. Various alternatives and modifications can be devisedby those skilled in the art without departing from the invention.Accordingly, the present invention is intended to embrace all suchalternatives, modifications and variances.

1. A threaded fastener having a driver-engageable recess formed at anend thereof, the recess comprising: a central core having a bottomregion; a plurality of wings radiating outwardly from the central core,the wings each being defined by a pair of sidewalls and an outertransition surface adjoining the sidewalls, the outer transition surfaceextending from a top of the recess and connected to the bottom regionand forming a bottom region transition edge at the intersection of thebottom region and the outer transition surface; at least one innertransition surface connecting a sidewall of a first wing to a sidewallof a second wing, the first and second wings being adjacent to eachother; a groove in the inner transition surface extending in a radiallyoutward direction from the inner transition surface, the grooveextending from a first distance from the bottom region transition edgeto a second distance from the bottom region transition edge, the firstdistance being non zero.
 2. The threaded fastener of claim 1, whereinthe groove extends to a top of the recess.
 3. The threaded fastener ofclaim 1, wherein the groove comprises a first and second groove walls,the first and second groove walls meeting at a groove apex, the grooveapex being tapered radially inward toward a longitudinal axis of thefastener as the recess groove extends in a direction from the top of therecess toward the bottom region.
 4. The threaded fastener of claim 3,wherein the groove apex is tapered at an angle of between about 8degrees and about 12 degrees, inclusive, from the longitudinal axis ofthe fastener.
 5. The threaded fastener of claim 3, wherein the grooveapex is tapered at an angle of 10.4 degrees from the longitudinal axisof the fastener.
 6. The threaded fastener of claim 3, wherein there isan angle of between about 40 degrees and about 60 degrees, inclusive,between the first and second groove walls.
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 17. The threadedfastener of claim 1, wherein at least one of the sidewalls is configuredto define a segment of a spiral.
 18. The threaded fastener of claim 1,wherein at least one of the inner transition surfaces comprises aninterference surface having a top and a distance from the top to thebottom region transition edge is less than the first distance.
 19. Afastener system comprising: a fastener comprising: a central recess corehaving a bottom region; a plurality of wings radiating outwardly fromthe central recess core, the wings each being defined by a pair ofrecess sidewalls and a recess outer transition surface adjoining therecess sidewalls, the recess outer transition surface extending from atop of the recess and connected to the bottom region and forming abottom region transition edge at the intersection of the bottom regionand the outer transition surface; at least one recess inner transitionsurface connecting a recess sidewall of a first wing to a recesssidewall of a second wing, the first and second wings being adjacent toeach other; a groove in the inner transition surface extending in aradially outward direction from the inner transition surface, the grooveextending from a first distance from the bottom region transition edgeto a second distance from the bottom region transition edge, the firstdistance being non zero. a driver for engaging the recess of thefastener, the driver comprising: a shank portion and a recess-engagingportion formed at an end of the shank portion, the recess-engagingportion comprising a central driver core having an end region and aplurality of lobes radiating outwardly from the driver central core,each lobe being defined by a pair of driver sidewalls and a driver outertransition surface adjoining the driver sidewalls, the driver outertransition surface extending from the shank portion and connected to theend region and forming an end region outer transition edge at theintersection with the driver end region; at least one driver innertransition surface connecting a driver sidewall of a first lobe to adriver sidewall of a second lobe, the first and second lobes beingadjacent to each other; and a stabilizing rib on the driver innertransition surface extending in a radially outward direction from thedriver central core, the stabilizing rib extending from a first distancefrom end region outer transition edge to a second distance from the endregion outer transition edge, the first distance being non-zero.
 20. Thefastener system of claim 19, wherein the groove comprises a first andsecond groove walls, the first and second groove walls meeting at agroove apex, the groove apex being tapered radially inward as the recessgroove extends in a direction from the top of the recess toward thebottom region.
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 31. The fastener system of claim 20,wherein the groove apex intersects the inner transition surface at thefirst distance from the bottom region transition edge.
 32. The fastenersystem of claim 20, wherein the stabilizer apex meets the innertransition surface at the first distance from the end region outertransition edge.
 33. The fastener system of claim 20, wherein a firstand second intersection line, formed at the intersection of the firstand second groove walls with the recess inner transition surface,respectively, form an angle of between about 6.5-7.0 degrees between thegroove walls.
 34. The fastener system of claim 19, where the driverinner transition surfaces are tapered at an angle with respect to thelongitudinal axis of the driver and the recess inner transition surfacesare tapered at an angle with respect to the longitudinal axis of therecess.
 35. The fastener system of claim 34, wherein the driver innertransition surface taper angle is less than the recess inner transitionsurface taper angle.
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 43. (canceled)44. The fastener system of claim 19, wherein at least one of the recessinner transition surfaces comprises an interference surface having a topdefined by a design recess interference region and a distance from thetop to the bottom region transition edge is less than the first distanceto the groove.
 45. The fastener system of claim 19, wherein at least oneof the driver inner transition surfaces comprises an interferencesurface having a top defined by a design driver interference region anda distance from the top to the end region outer transition edge is lessthan the first distance to the stabilizing rib.
 46. The fastener systemof claim 43, further comprising a clearance distance between the top ofthe recess interference region and the groove.
 47. The fastener systemof claim 45, further comprising a clearance distance between the top ofthe driver interference region and the rib.
 48. A method of forming athreaded fastener having a driver-engageable recess formed at an endthereof, the method comprising: using a punch to form the recess, thepunch including: a central core having a bottom forming portion; aplurality of wing forming portions radiating outwardly from the centralcore, the wing forming portions each being defined by a pair of sidewallforming portions and an outer transition surface forming portionadjoining the sidewall forming portions, the outer transition surfaceforming portion connected to the bottom region forming portion andforming a bottom region transition edge forming portion at theintersection of the bottom region forming portion and the outertransition surface forming portion; at least one inner transitionsurface forming portion connecting a sidewall forming portion of a firstwing forming portion to a sidewall of a second wing forming portion, thefirst and second wing forming portions being adjacent to each other; agroove forming portion in the inner transition surface forming portionextending in a radially outward direction from the inner transitionsurface forming portion, the groove forming extending from a firstdistance from the bottom region transition edge forming portion to asecond distance from the bottom region transition edge forming portion,the first distance being non zero.
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